Filling small holes in metal enclosure

[xorophone]

Hello! Once in a while you drill a hole or two in the wrong spot and while trying to find a solution, your vision slowly degrades because of the tears filling your eyes. Of course bigger holes are going to be hard to fix and you might as well just scrap the enclosure and start over. (Or use it to try out new paint and stuff in the future.)

How about smaller holes? Is there a filler or something I can use to fill the hole? Something that sits very well in the hole and becomes invisible after painting. I personally use spray paint so it doesn't need to be very heat resistant. Just 10 minutes ago I drilled a 2mm hole on the underside of an enclosure in the completely wrong spot. Of course I can just put a small screw in it, but if I did that, my perfectionism would kill me.

Thanks!

[DK1]

JB Weld? Bondo?

[rutabaga bob]

They make a product called steel putty or some such...I usually use it to attach standoffs and the like.  You break off a piece, knead it for a bit, and apply where needed.  It can be sanded and painted when it hardens.

[EBK]

JB Weld works quite well, ever for larger holes.  I've fixed misplaced 1/4" jack holes with it.  I used parchment paper as a backing, held in place by a larger piece of gaffers tape big enough to hang over all the edges (because tape won't stick to parchment paper).  Once fully cured, JB Weld is easily sanded flush, and redrilling is no problem. 

[xorophone]

Great! Thanks for the replies. I'll look up the products mentioned and see which one is the easiest to get ahold of where I live.

[xorophone]

JB Weld works quite well, ever for larger holes.  I've fixed misplaced 1/4" jack holes with it.  I used parchment paper as a backing, held in place by a larger piece of gaffers tape big enough to hang over all the edges (because tape won't stick to parchment paper).  Once fully cured, JB Weld is easily sanded flush, and redrilling is no problem.

Do you know which JB Weld product you used?

[EBK]

JB Weld works quite well, ever for larger holes.  I've fixed misplaced 1/4" jack holes with it.  I used parchment paper as a backing, held in place by a larger piece of gaffers tape big enough to hang over all the edges (because tape won't stick to parchment paper).  Once fully cured, JB Weld is easily sanded flush, and redrilling is no problem.

Do you know which JB Weld product you used?

It was either J-B Weld twin tube or KwikWeld twin tube.  Pretty sure it was KwikWeld (all my tools are boxed up for a move at the moment). 

Just noticed they have a product called TankWeld.  That would be great for patching up a Green Russian Big Muff, I bet. 

[xorophone]

JB Weld works quite well, ever for larger holes.  I've fixed misplaced 1/4" jack holes with it.  I used parchment paper as a backing, held in place by a larger piece of gaffers tape big enough to hang over all the edges (because tape won't stick to parchment paper).  Once fully cured, JB Weld is easily sanded flush, and redrilling is no problem.

Do you know which JB Weld product you used?

It was either J-B Weld twin tube or KwikWeld twin tube.  Pretty sure it was KwikWeld (all my tools are boxed up for a move at the moment). 

Just noticed they have a product called TankWeld.  That would be great for patching up a Green Russian Big Muff, I bet. 

Ah, so I'm guessing I just need to look for a steel reinforced epoxy. Other brands probably work fine too, but I'll try to get some from J-B Weld.

Thank you, Eric! Good luck with the move!

[greaser_au]

My suggestions:
- filler can be anything hard setting and plastic-like (i.e not plaster of paris ), like epoxy (either filled like JB Weld or unfilled like Araldite), polystyrene/nitrocellulose (car body filler).
- a very light countersink either side of the panel and some heavy scratching ('keying') inside the hole - coarse sandpaper or file - wouldn't hurt if you can do it...
- make sure you remove ALL traces of grease and oil from the area to be filled.
- wipe some of the filler onto the surfaces you want it to stick to with a little pressure to break any surface tension before loading the filler.
- bigger holes may need a little backing up, especially if the fill is to be any more than cosmetic.
- mix the filler carefully to avoid getting air mixed in.
- many of these filler materials will shrink a little bit during curing, so overfill the visible 'face' side slightly (will require sanding back after).

david

[EBK]

My suggestions:
- filler can be anything hard setting and plastic-like (i.e not plaster of paris ), like epoxy (either filled like JB Weld or unfilled like Araldite), polystyrene/nitrocellulose (car body filler).
- a very light countersink either side of the panel and some heavy scratching ('keying') inside the hole - coarse sandpaper or file - wouldn't hurt if you can do it...
- make sure you remove ALL traces of grease and oil from the area to be filled.
- wipe some of the filler onto the surfaces you want it to stick to with a little pressure to break any surface tension before loading the filler.
- bigger holes may need a little backing up, especially if the fill is to be any more than cosmetic.
- mix the filler carefully to avoid getting air mixed in.
- many of these filler materials will shrink a little bit during curing, so overfill the visible 'face' side slightly (will require sanding back after).

david

all great tips.  I especially like the idea of a light countersink on each side.  Would create a nice double flange to keep the epoxy "coin" from popping out in either direction.

[slacker]

stick extra LEDs in them, you can never have too many LEDs

[EBK]

stick extra LEDs in them, you can never have too many LEDs

Just imagining a 10mm LED added to fill a large misplaced hole.   

[anotherjim]

Blind grommets. Seems to be important enough to have specialist suppliers...
https://www.grommets.co.uk/products/grommets/blind-rubber-grommets/
If I went to trouble of making a flawless fill of the hole, there's a very good chance I'll change my mind afterwards and decide I do want a hole there after all.

[EBK]

Blind grommets. Seems to be important enough to have specialist suppliers...
https://www.grommets.co.uk/products/grommets/blind-rubber-grommets/
If I went to trouble of making a flawless fill of the hole, there's a very good chance I'll change my mind afterwards and decide I do want a hole there after all.

I think you misdrill more carefully than I misdrill. 

[xorophone]

My suggestions:
- filler can be anything hard setting and plastic-like (i.e not plaster of paris ), like epoxy (either filled like JB Weld or unfilled like Araldite), polystyrene/nitrocellulose (car body filler).
- a very light countersink either side of the panel and some heavy scratching ('keying') inside the hole - coarse sandpaper or file - wouldn't hurt if you can do it...
- make sure you remove ALL traces of grease and oil from the area to be filled.
- wipe some of the filler onto the surfaces you want it to stick to with a little pressure to break any surface tension before loading the filler.
- bigger holes may need a little backing up, especially if the fill is to be any more than cosmetic.
- mix the filler carefully to avoid getting air mixed in.
- many of these filler materials will shrink a little bit during curing, so overfill the visible 'face' side slightly (will require sanding back after).

david

Ah, those are some great tips! Thank you so much, David!

That probably means I'll be able to use my "normal" epoxy too and not have to buy the steel reinforced stuff. I've got some Loctite Power Epoxy already.

[xorophone]

Blind grommets. Seems to be important enough to have specialist suppliers...
https://www.grommets.co.uk/products/grommets/blind-rubber-grommets/
If I went to trouble of making a flawless fill of the hole, there's a very good chance I'll change my mind afterwards and decide I do want a hole there after all.

Thanks Jim! This time I'm 100% sure I don't want the hole, so I'll probably just fill it with epoxy this time, but nice product to keep in mind!

[davepedals]

I've used epoxy before, but prefer jb weld, simple to work with and strong.  Easy to sand as well. Try ace hardware, home depot, Lowe's, or order from amazon.

[deadastronaut]

If in the uk...  chemical metal.   

[EBK]

If in the uk...  chemical metal.   

Or just order J-B Weld through amazon.co.uk

(I'm assuming the Amazon experience there is similar to here in the US -- competitively low prices with fast shipping.  Don't get me started talking about Amazon Prime.  That sh*t is magical!  -- Not affiliated, in case my sig didn't make that clear)

[xorophone]

I've used epoxy before, but prefer jb weld, simple to work with and strong.  Easy to sand as well. Try ace hardware, home depot, Lowe's, or order from amazon.

I've actually filled the hole with epoxy already. I filled it yesterday so I'm going to check on it today. Hopefully it's good enough!

I'll probably still order some J-B Weld and use it in the future, though.